Industry Solutions for the Building Materials Industry
Crushers, mills and mixers in the building materials industry process tonnes of clinker, cement, gravel and sand every day. These mineral bulk solids are hard and angular. They abrade components, and in crushing tools massive impact stress is added on top.
With every operating hour, grinding rolls lose their profile, crusher plates their contour and chutes their wall thickness. Unplanned replacements cost production time and money.
We supply wear protection solutions, spare parts and welding consumables that target exactly these problems and keep your components in service longer.
Typical Welding Defects on Crushers, Mills and Conveying Elements
Carbide-rich hard-facing layers in crushers and mills only hold when heat management is correct. The by far most common damage pattern in the building materials industry arises precisely here. We explain what causes it and how we prevent it.
Problem: Cracks Due to Incorrect Heat Management and Dilution
Carbide-rich hard-facing layers on grinding rolls, crusher rolls and wear plates are sensitive to heat management. If heating is uneven, cooling is too rapid, or the layer is excessively diluted with the base material, microstructural stresses arise and the hard top layer cracks.
Our Solution: Controlled Heat Management and Defined Dilution
With preheating, matched welding parameters and a controlled dilution level, we keep residual stresses low and ensure the hard-facing layer remains crack-free.
Suitable Welding Consumables for Crushers, Mills and Conveying Elements
Clinker, raw meal, gravel or sand: each bulk solid attacks components differently. That is why capilla aligns the filler material, welding process and layer structure to the bulk solid specification — not to a standard recipe. Where fine abrasion dominates, carbide-rich top layers are used; where crushers impact, tougher alloys with a buffer layer. For mixed loading, single or multi-layer build-ups are applied, matched to the base material. Use the wear types below to find suitable welding consumables for each application area.
Corrosion
Show products
Metal-to-metal friction wear
Show products
Impact stress
Show products
Temperature
Show products
Spare and Wear Parts for the Building Materials Industry
Mills, crushers and mixers in cement and building materials production are exposed to extreme abrasion. Find suitable wear and spare parts for your equipment here:
Fully Automated Overlay Welding and Additive Manufacturing
In the Laser Competence Centre, capilla brings together modern technologies for coating and component manufacturing.
Here, components are specifically heat-treated, wear-resistant layers are applied and complex components are manufactured using additive processes such as 3D cladding.
This enables solutions that go beyond conventional welding applications and make components sustainably more capable.
Andreas Frische
Technical Management
Do you have wear problems, recurring damage or would you like to operate your equipment more economically?
Our experts support you in selecting suitable welding consumables, in heat treatment of components and in developing long-lasting solutions.
Together we find the approach that suits your application technically and economically.
+49 5202 97790-54
Available from 07:45 - 16:30
a.frische@capilla-gmbh.de
Available from 07:45 - 16:30
Why capilla
Holistic Approach
From welding consumable to finished component – all solutions interlock.
Focus on Wear
Specialisation in applications with high abrasion and mechanical stress.
Practical Consulting
Analysis of real applications rather than theoretical recommendations.
Own Technologies
Laser Competence Centre for coating and additive manufacturing.
capilla Wear Protection to Bulk Solid Specification
We do not work with standard recipes. Whether bulk solid, medium or workpiece, what always matters is the actual load acting on the component. Grain size, hardness, temperature, flow or chemical aggressiveness determine which type of wear dominates and which protection really fits.
Before we specify welding consumable, process and layer structure, we analyse the operating conditions. This produces a solution that fits your component. Tested filler materials and defined parameters are part of that, supplemented by standards-compliant documentation for safety-critical components.
Frequently Asked Questions on Wear Protection in the Building Materials Industry
Industry solutions for the building materials industry include wear-resistant hard-facing layers, repair welding and component-specific welding consumables for cement plants, concrete plants, gravel and sand works, asphalt mixing plants and recycling plants for construction rubble. They are applied to heavily loaded equipment such as jaw crushers, impact crushers, roller mills and vertical roller mills, as well as throughout bulk handling systems, with the aim of longer service lives and reduced downtime.
In crushing plants such as jaw, impact and hammer crushers, impact stress dominates; in grinding plants such as roller mills, vertical roller mills and ball mills, fine abrasive wear by clinker, cement and raw meal. In chutes, screws and conveying elements of bulk handling technology, sliding wear from continuous bulk solid conveying is added. Abrasion and impact often occur in combination: layer structure and alloy must be designed accordingly.
Wear protection is matched to the respective bulk solid: grain size, hardness and impact energy determine the alloy and layer structure. For fine abrasive bulk solids from cement production and clinker grinding (clinker, cement, raw meal), carbide-rich hard-facing layers are used; for impact-stressed bulk solids in gravel and sand works or construction rubble recycling plants (gravel, rubble, chippings), tougher alloys with buffer layer. For mixed loading, wear protection is built up in multiple layers.
In crushing plants, jaw plates, impact bars, crusher rolls and impact elements are most heavily stressed. In roller and vertical roller mills, grinding rolls, grinding tracks and mill floors are subject to high abrasion. In bulk handling technology, material flow and wear meet at chutes, screws, wear liners, wear plates, screen plates, hopper plates and pipe bends; in processing additionally at loader bucket edges. These wear parts can be protected or reconditioned by overlay welding.
Grinding rolls in roller mills and vertical roller mills (VRM) in the cement industry are protected with multi-layer hard-facing: a tough buffer layer compensates for stresses to the base material, with a hard, carbide-rich top layer against abrasion by clinker and raw meal on top. Alloy and layer thickness are designed for the respective mill and grinding material, often as targeted profile overlay on the most heavily stressed zones.
Highly alloyed, chromium carbide-rich or complex carbide flux-cored wires and electrodes are used, matched to the ratio of abrasion to impact. In cement production and on vertical roller mills, welding consumables with a high carbide content dominate against fine abrasion; in impact and hammer crushers for gravel and construction rubble processing, tougher matrices with buffer layer. A preliminary component and material analysis ensures that welding consumable and layer structure match the specific application.
Overlay welding is worthwhile for large, expensive and heavily stressed components in cement plants, gravel and sand works and construction rubble recycling plants: grinding rolls in roller and vertical roller mills, crusher rolls, jaw and impact plates, hammer crusher tools as well as mixer paddles and wear liners. Targeted re-overlay extends service life many times over and is usually significantly more economical than replacement, including shorter downtime.
On crushers, roller mills and vertical roller mills in the cement industry, wear protection is applied in multiple layers: a tough buffer layer compensates for different base materials and stresses, with a hard, carbide-rich top layer against abrasion by clinker, raw meal or gravel on top. For pure impact stress on impact and hammer crushers in gravel or construction rubble recycling, the hard-facing is designed to be tougher and with a lower carbide content.
For screws, slides and chutes in bulk handling plants of the building materials industry, chromium carbide-rich or complex carbide flux-cored wires are used, matched to the conveyed bulk solid. For fine abrasive media from cement production or clinker grinding, high carbide contents dominate; for impact-stressed slides in gravel and ballast processing, tougher alloys with buffer layer. This keeps material flow and service life stable even with continuous bulk solid conveying.
Industry solutions for cement plants include wear-resistant overlay layers and repair welding for grinding rolls, grinding tracks, mill floors, mixer paddles, chutes and wear plates, particularly in vertical roller mills, roller mills and ball mills. Design is based on clinker or raw meal specification, often in multiple layers with defined hardness distribution from tough buffer layer to hard top layer. The aim is high service lives and plannable maintenance intervals in ongoing cement production.